详情描述

  

I. Product Overview:

YFA-F Type hydraulic valve test bench, which is developed based on our years of experience in manufacturing valve testing equipment, strictly adheres to GB/T13927-2008 "General Valve Pressure Test" and JB/T26480-2011 "Testing and Inspection of Valves."American Petroleum Institute StandardDesign and production are required in accordance with API598 and other specifications for test pressure requirements.

This unit integrates hydraulic, mechanical, electrical systems, pressure supply units, and medium storage circulating water tanks into one. The entire testing process is automatically controlled and executed by hydraulic and electrical components. It boasts advantages such as reasonable structure, comprehensive functions, stable performance, convenient operation, and high level of automation. It is widely used in high, medium, and low-pressure direct flanged valve testing for pressure sealing performance and shell strength endurance. Suitable valve types include gate valves, stop valves, check valves, ball valves, and more. It is ideal for valve manufacturers, the petrochemical industry, and hydroelectric power stations.Natural GasIdeal valve testing and inspection equipment for industries such as pipe fitting manufacturers, wastewater treatment plants, and valve maintenance stations.

II. Specification Range:

DN15-1200mm

3. Pressure Range: 1.6-63.0 (MPa) / 150-2500 (Class)

IV. Performance Features:

Valves such as gate valves, stop valves, check valves, and ball valves suitable for direct flange connections, featuring a sealing method using flange face sealing and hydraulic clamps to tighten the back of the flange, with adjustable clamping force. Test results show no external force interference. During the valve testing process, the right working disc can be rotated 90 degrees, particularly suitable for gas sealing performance tests. The other working disc can be moved forward and backward, with the length clearance spacing freely adjustable, allowing for unrestricted valve length, significantly enhancing work efficiency.

Clamping Method: Each dual-action disk is equipped with a removable hydraulic clamping mechanism. It can automatically synchronize and adjust the position of the clamping jaws according to various valve specifications, achieving automatic centering and positioning. The hydraulic clamping jaws automatically grip the back of the valve flange, with adjustable clamping force, having no external force impact on the tested valve itself. The clamping process is fully controlled by an integrated button, with hydraulic components executing the operation.

 

Hydraulic Valve Test Bench Working Principle and Operation Method:

I. Working Principle:

Select a sealing blank compatible with the valve model and install it on the equipment. Push the circuit breaker, the equipment power indicator light illuminates. Press the oil pump start button to operate the hydraulic system motor. Ensure the motor runs in the correct direction (clockwise). Move the left sliding frame back beyond the length of the test valve. Radially move the left and right clamps beyond the outer diameter of the valve flange. Extend the left and right clamps axially beyond the thickness of the valve flange.

Secure the test valve flange tightly against the right-hand workbench using a blind flange, aligning it with the center position. Move the radial clamp, position it close to the valve flange, and press the clamp button to reduce the clamp spacing, pressing firmly against the back of the valve flange to ensure the valve does not come loose.

Slide the left-hand cart towards the right-hand workbench, positioning it close to the opposite end of the valve flange being tested. Press it against the left-hand test blind flange and align it to the center. Move the left radial clamp closer to the valve flange, press the clamp button to shorten the clamp travel, and press against the back of the valve flange, completing the overall clamping of the valve.

 

Section 2: Sealing Pressure Test Method:

1. Fill the hydraulic system oil tank with 30#-46# hydraulic oil or 20# mechanical oil, ensuring the oil level does not fall below the oil gauge's lower limit.

2. Power on, press the oil pump start button, and check if the motor rotates in the correct direction (in a clockwise manner).

Adjust the hydraulic system pressure to 5.0 MPa for normal operation.

4、The tested valve flange is sealed tightly against the right workbench with a test blind plate, aligned with the center position. Move the radial clamp, position it near the valve flange, press the clamp button to reduce the gap between the jaws, and securely press against the back of the valve flange to ensure the valve does not come loose.

5. Close: Left water inlet valve → Total air inlet valve → Right pressure relief valve → Test valve → Right pressure gauge switch.

6. Open: Right water inlet valve → Main water inlet valve.

7. Refer to the (Pressure Requirement Chart for Cylinder Clamping) to adjust the clamping pressure. For pressures exceeding the pump source by 5.0 Mpa or more, press the (Right Claw Pressure Increase) button to increase the pressure to the required clamping level. Press the (Top-Right Flip) button to flip the working plate to a horizontal position.

8. All assembly is complete. Set the low-pressure pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (take the valve sealed at 4.0MPa as an example, adjust the red pointer of the electrical contact pressure gauge to 4.0MPa).

9. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve cavity is fully filled with water. The low-pressure pump will automatically stop, and the high-pressure pump will automatically start to supply pressure. When the high-pressure water reaches the set value of 4.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check the sealing surface of the valve, the connection areas, and whether there is any leakage on the valve body surface, and if the pressure gauge has any dips, to confirm if the sealing surface performance is up to standard. After the test is complete, open the (pressure relief valve) switch, exhaust the pressure, and proceed to the next test.

Note: The process of loading and testing in the left-hand direction is the same as in the right-hand direction.

Section 3: Method of Strength and Pressure Testing

1. Intensity pressure test: Based on the sealed test fixture process, advance the left-hand movable frame to the right-hand workbench, approaching the opposite end valve flange. Press tightly against the left-hand test blind flange, aligning with the center position. Move the left radial clamp jaw towards the valve flange, press the clamp button to shorten the jaw travel, and securely press against the back of the valve flange, completing the overall fixture of the valve.

2. Refer to the pressure required for cylinder clamping table, and increase the pressure to the required value. Once everything is clamped, set the low-pressure water pump electrical contact pressure to 1.8 (Mpa). Set the electrical contact pressure (for strength pressure, use the 6.0 MPa valve as an example) by adjusting the red pointer on the electrical contact pressure gauge to 6.0 MPa.

3. Open: Right inlet valve → Left inlet valve → Valve under test.

4. Close: Total intake valve → Right pressure relief valve → Left pressure relief valve → Right pressure gauge switch → Left pressure gauge switch.

5. Start the low-pressure water pump. When the low-pressure water pressure reaches the set value of 1.8 (MPa), it indicates that the valve chamber is already filled with water. The low-pressure pump will automatically stop, and the high-pressure pump will automatically start to supply pressure. When the high-pressure water reaches the set value of 6.0 (MPa), the high-pressure pump will automatically stop, and enter the pressure holding timing period (such as 2 minutes/client-defined). Check the valve connection areas, as well as for any leaks on the valve body surface and if the pressure gauge is stable, to confirm if the valve strength pressure test is合格. After the test is complete, open the (pressure relief valve) switch, exhaust the pressure, release the clamps, and remove the valve.

 

VI. Usage Precautions and Requirements：

1. The site should be arranged in a level indoor space, properly leveled, and the footings secured with concrete. It is suitable for use in environments with temperatures ranging from (1-40)℃ at normal conditions or in heated workshops during winter. The area should be free from high concentrations of dust and corrosive gases, and should not be near areas with grinding wheels or polishing machines with poor conditions. Good ventilation is required, and at least a 1m space should be left around the equipment for ease of operation and maintenance.

2. Operators must undergo professional training before starting work, adhere to standard procedures, and strictly prohibit the use beyond specifications or pressure. Non-specialists are advised not to operate.

3. Operators are strictly prohibited from leaving their posts during the pressure testing process. They must continuously monitor the pressure to prevent it from exceeding safe limits.

4. After completion of the test, the pressure must be released to zero before the clamps can be released. The power should be disconnected when not in use.

5. All moving parts on the testing bench should be regularly lubricated to maintain clean and smooth operation.

6. Select 46-grade anti-wear hydraulic oil (use anti-freeze 46-grade anti-wear hydraulic oil below 0℃), ensuring the oil level does not fall below the gauge's lower limit. Regularly inspect the oil level and hydraulic oil; a flush should be performed after one year of use.Wash OilBox, change to new oil.

7. Water source must be clean and free of impurities. If water quality deteriorates, it should be changed promptly. Add new rust prevention powder, meet testing requirements. To ensure that testing valves are not corroded, it is usually necessary to add rust prevention powder regularly to the recirculating water tank and prevent the medium water from causing rust to affect the normal operation of pipes, pumps, and check valves.

Note: Common rust-proof powders include:Sodium NitriteSodium sulfonate, potassium benzenesulfonate (non-toxic powder).

8. The equipment work surface should be kept clean, and there should be no debris between the valve flange being tested and the pressure test blank flange.